CHAPTER 3 (a)

Design Process & The Role of

CAD

MEC435 COMPUTER-
AIDED DESIGN
1
 3.1 DESIGN PROCESS
• Any product begins with a need based on customers’ and
markets’ demand before being translated into a finished
product.
• Main processes involve:
– Design process.
– Manufacturing process.

2
 Types of Design
• Original Design
–Also called innovative design.
–A truly original design involves invention.
–Successful original design rarely occur, but when they do occur they will give
a big impact to the market.
–E.g. Microprocessor.

• Adaptive Design
–Adapts a design from a known solution to fulfill a different need to produce a
novel application.
–Involves synthesis and are relatively common in design.
–E.g. Adapting the ink-jet printing concept to spray binder to hold particles in
place in a RP machine.

3
• Redesign
–Mostly practiced to improve an existing design.
–Usually does not involve the change in the working principle or concept if
the original design.
–Maybe changing some of the design parameters (e.g. materials, shape, etc.)
→ variant design.

• Selection Design
–Most design uses standards components supplied by vendors.
–Implemented by selecting certain components base on the needed
performance, quality and cost from catalogs of potential vendors.

• Industrial Design
–Deals with improving the appeal of a product to the human senses especially
its visual appeal (aesthetic).
–More artistic than engineering but still an important aspect of kinds of design.
–Consideration on how the human user can best interface with the product.
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Closed Loop Product Cycle
Product Cycle in Conventional Manufacturing
Environment
Product Cycle in Computerized Manufacturing
Environment
 What is Design?
• Design is an innovative and highly iterative process.

• It is also a decision-making process

• The process of identifying and deeply understanding a problem or need, thinking

creatively, using sound decision-making processes to identify the best solution, and
using project management and teamwork skills to drive the entire process, implement
the solution, test it, and modify it.

• Engineering Design integrates mathematics, basic sciences, engineering sciences,

economics and other subjects for the creation of components, systems, product and
processes to satisfy specific needs and constraints (i.e., economics, safety, health,
environmental and social factors, the requirements of standards and legislation, and
other consideration such as maintainability, serviceability, and manufacturability)
 Morphology of Design
• Morphology means ‘a study of form or structure’.

• Morphology of design refers to the time based sequencing of

design operations. It is a methodology of design by which
ideas about things are converted into physical objects. The
logical order of different activities or phases in a design
project is called the morphology of design.

• A design project goes through a number of time phases.

Morphology of design refers to the collection of these time
phases.

• The morphology of design as put forward by Morris Asimow

can be elaborated through seven phases .
 7 Phases of Design Process

Phase 1 • Conceptual Design

Phase 2 • Embodiment Design

Phase 3 • Detail Design

Phase 4 • Planning for Manufacture

Phase 5 • Planning for Distribution

Phase 6 • Planning for Use

Phase 7 • Planning for Retirement

Conceptual Design

• This stage is also called feasibility study. A design project always

begins with a feasibility study. The purpose and activities during
feasibility study are:
• To ascertain there really exists a need i.e. the existence of need must
be supported by necessary evidences, rather than the outcome of
one's fancy
• Search for a number of possible solutions
• Evaluate the solutions
• i.e. is it physically realisable?
• Is it economically worthwhile?
• Is it within our financial capacity?
Embodiment Design
• This is the stage art which the concept generated in the feasibility
study is carefully developed. The important activities done at this
stage are:
• Model building & testing
• Study the advantages and disadvantages of different solutions.
• Check for performance, quality strength, aesthetics etc.

Detail Design
• Its purpose is to furnish the complete engineering description of the
tested product. The arrangement, from, dimensions, tolerances and
surface properties of all individual parts are determined. Also, the
materials to be used and the manufacturing process to be adopted
etc. are decided. Finally, complete prototype is tested.
Planning for Manufacture
• This phase includes all the production planning and control activities
necessary for the manufacture of the product. The main tasks at this phase
are
• Preparation of process sheet, i.e. the document containing a sequential
list of manufacturing processes.
• Specify the condition of row materials.
• Specify tools & machine requirements.
• Estimation of production cost.
• Specify the requirement in the plant.
• Planning QC systems.
• Planning for production control.
• Planning for information flow system etc.
 Planning for Distribution
• The economic success of a design depends on the skill exercised in
marketing. Hence, this phase aims at planning an effective
distribution system. Different activities of this phase are
• Designing the packing of the product.
• Planning effective and economic warehousing systems.
• Planning advertisement techniques
• Designing the product for effective distribution in the prevailing
conditions.
Planning for Use / Consumption

• The purpose of this phase is to incorporate in the design all necessary

user- oriented features. The various steps are
• Design for maintenance
• Design for reliability
• Design for convenience in use
• Design for aesthetic features
• Design for prolonged life
• Design for product improvement on the basis of service data.
Planning for Retirement

• This is the phase that takes into account when the product has
reached the end of useful life. A product may retire when
• It does not function properly
• Another competitive design emerges
• Changes of taste or fashion
• The various steps in this phase are
• Design for several levels of use
• Design to reduce the rate of obsolescence.
• Examine service-terminated products to obtain useful information.
 The Phase Of Design

Define Gather Concept Evaluation of Product Configuration Parametric

Problem Information Generation Concepts Architecture Design Design

Phase I. Phase II.

Conceptual Embodiment
Design Design

Phase III.
Detail Design

Phase VII. Phase VI. Phase V. Phase IV.

Planning for Planning for Planning for Planning for
Retirement Use Distribution Manufacture
Engineering Design Process 1st Three Phases

Define problem Gather Concept Evaluate & select

information generation concept
Problem Creativity methods Decision making
statement Internet Patent Brainstorming Selection criteria
Benchmarking Technical articles Functional models Pugh chart
QFD Trade journal Decomposition Decision matrix
PDS Consultants Systematic design
Project planning AHP
methods
Phase 1- conceptual design

Configuration
Parametric design
design
Product Detail design
Robust design
architecture Preliminary
selection of Set tolerance Engineering
materials and DFM, drawings
Arrangement of
manufacturing DFA, Finalize PDS
physical elements
process DFE
Modularity Tolerances
Modeling
Sizing of parts
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Phase 2- embodiment design Phase 3- detail design
 The Phase Of Design – Phase 1

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. •Feasibility Study.

Conceptual
Design •Requires greatest creativity, involves the most
uncertainty and requires coordination among many
functions in the business organization.

•Discrete activities to be considered:

− Identification of customer needs
− Problem definition
− Gathering information
− Conceptualization
− Concept selection
− Design review
 The Phase Of Design – Phase 1

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. •Most important steps in the engineering design

Conceptual process is identifying customer needs.
Design
• The customer needs can be gained from:
– Interviewing customers
– Focus group
– Customer survey
– Customer complaints

• Tools to achieve this:

– Benchmarking
– QFD
– PDS
 Benchmarking
Method for measuring company operation against the best company inside and outside of the industries.
Select the product, process, or functional area that is to be benchmark.
Identify the performance metrics that will be measured and used for comparison.
Compare the best in class product or process with the in house equivalent using the performance metrics.
Specified program and actions to meet an exceed the competition

QFD – Quality Function Deployment Color

A planning and problem solving tool that is finding growing acceptance for translating customer requirements into
engineering characteristics of a product.
Alargely graphical method that systematically looks at all the elements that go into the product definition.
Helps organisations seek out both spoken and unspoken needs.
QFD links the needs of the customer (end user) with design, development, engineering, manufacturing, and service functions. A
process devised to identify the voice of customer and channel it through the entire product development process (PDP).
Also known as ‘House of Quality’

PDS – Product Design Specification

A statement of what a product to be designed is intended to do.
Its aim is to ensure the development of a product meets the need of the users.
The PDS is a specification of what is required but not the specification of the product itself.
QFD- Quality Function Deployment

• Identify customer wants

• Identify how the good/service will satisfy
customer wants
• Relate customer wants to product hows
• Identify relationships between the firm’s
hows
• Develop importance ratings
• Evaluate competing products
• Compare performance to desirable
technical attributes

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Target
 Product Design Specifications (PDS)
• A document that contains all of the facts related to the outcome of
the product development (document listing the problem in detail).
• It should avoid forcing the design direction toward a particular
concept and predicting the outcome.
• Should be understood that the PDS is evolutionary and will change
as the design process proceeds.
• It is important to work with the customer and analyse the
marketplace to produce a list of requirements necessary to
produce a successful product.
• The designer should constantly refer back to this document to
ensure designs are appropriate.
 Product Design Specifications (PDS)
Example: PDS

1. What is the product going to be?

2. What are the dimensions of the product?
3. What materials does the product require?
4. What is the estimate cost of the materials?
5. What tools/technology will be used to work on the project?
6. Are the tools/technology accessible, or will special arrangements need to be made?
7. What is the time estimate for completing the project?
8. Where will the product be worked on primarily?
9. Will an outside company be used to complete the project?
10. Will materials need to be ordered? If so, how much time should be allotted for
shipping, ordering, etc?
11. Will an expert in the field need to assist with the creation of the product? If so,
when will this person be contacted to set up a mutually convenient time to meet?
12. Who will benefit from the benefit from the creation of the product?
13. Why is it necessary to create this product?
14. How will the product demonstrate technical knowledge?
PDS TEMPLATE
 Product Design Specifications (PDS)

PRODUCT DESIGN SPECIFICATION EXAMPLE 1

Product: Lightweight wheel for Formula Student car.

Weight :Maximum 3kg

Size :13” diameter;
15-25mm centre thickness
Timescale :18 weeks from initial phase to manufacture.
Cost :Maximum RM300 per wheel
Quantity :4 on initial design run
Safety :-Design for fatigue life of 250000 cycles at approximately
1.4g loading
-Interface between centre and rims must be airtight
-Smooth surface finish
-Secure fittings
 Product Design Specifications (PDS)

Competition :There are few competitors in niche market, but

various racing wheel manufacturers.
Maintenance :Seals and bolts must be checked occasionally.
Customer :Lightweight motorsport / weekend racer.
Manufacturing Facilities :Dependent upon material
CNC and Casting in-house.
Other manufacturing must be out-sourced.
Installation :4 inch PCD 4 stud formation.
Materials :Range of materials to be modelled:
Aluminium 2024 T6
Steel
Plastics
PDS EXAMPLE 2
 The Phase Of Design – Phase 1

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. • Information from Internet

Conceptual – Engineering URLs
Design

• Patent Literature
– Intellectual Property
– Patents

• Handbook
 The Phase Of Design – Phase 1

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. • Brainstorming
Conceptual
Design
• Functional decomposition

• Morphological chart
 Concept Development, Evaluation and Selection

Generating Design Concepts

Brainstorming
−Most common method used by design teams for generating ideas for design
concepts in conceptual design.
− Think of all the possible limitations or shortcomings of the product.

Functional decomposition (breakdown)

− A logical approach for describing the transformation between the initial and final
states of a system or device.
−Physical decomposition → separating the product or subassembly directly into its
subsidiary subassemblies and components (output = physical decomposition block
diagram).
− Functional decomposition → a general description of a device is refined into more
specific arrangements of functions and subfunctions.
 Concept Development, Evaluation and Selection

Physical decomposition

Urban Car

Suspension Steering Braking

Chassis Power train
system system system

Functional decomposition

Power train

Variable valve
Direct injection 3.5 cc
timing

The controller is used to The gasoline is highly pressurized, and

The engine consist of 6
vary the operation of the injected via a common rail fuel line
pistons
open-closed valve directly into the combustion chamber
 The Phase Of Design – Phase 1

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. • Comparison Based on Absolute Criteria

Conceptual
Design
• Pugh’s Concept Selection Method

• Weighted Decision Matrix

 Concept Development, Evaluation and Selection

Morphological chart
− Representing and exploring all the relationships in multidimensional problems
regarding shape and form
 Concept Development, Evaluation and Selection

Concept Evaluation & Selection

Evaluation methods:
1. Pugh concept selection method.
2. Weighted decision matrix.
 Concept Development, Evaluation and Selection

• Pugh Concept Selection Method

• This method compares each concept relative to a reference or datum
concept.
• Each criterion determines whether the concept is better than, poorer
than or about the same as the reference concept.

• Steps in this Pugh concept selection method:

• 1. Choose the criteria by which the concepts will be evaluated
• - Can refer to QFD (House of Quality).
• 2. Formulate the decision matrix
• - Concepts on the row headings and criteria on the column headings.
• 3. Clarify the design concepts
• - Make sure every team member understand every concept developed.
 Concept Development, Evaluation and Selection

• 4. Choose the datum concept

• - Reference concept with which all other concepts are compared.
• 5. Run the matrix
• - Use a three-level scale, better (+), worse (-) or same (S).
• 6. Evaluate the ratings
• - Sum up the +, - and S ratings.
• 7. Establish a new datum and rerun the matrix
• - To gain added insight regarding the highest rated concept.
• 8. Examine the selected concept for improvement opportunities
• - Is there any improvement that can be done considering the worse
ratings gained for the selected concept.
Concept Development, Evaluation and Selection
Example 1:
Example 2:
Example 3:
 Concept Development, Evaluation and Selection

Weighted Decision Matrix

• Evaluating competing concepts by ranking the design criteria with weighting factors
and scoring the degree to which each design concept meets the criterion.
• Weighting factors:
- A 5-point scale (0-4) → knowledge of the criteria is not very detailed.
- An 11-point scale (0-10) → the information is more detail.
• The evaluation steps are quite similar to Pugh concept selection method but without
any datum.
 Concept Development, Evaluation and Selection
Example 1: Choice of cooker
Example 2:
Example 3: Career Choice
 The Phase Of Design – Phase 2

• Preliminary Design.

Product Configuration Parametric

Architecture Design Design
•Decisions are made in this design phase: strength,
material selection, size, shape, and spatial compatibility.

•Any major changes beyond this design phase become Phase II.
very expensive. Embodiment
Design
 The Phase Of Design – Phase 2

•Arrangement of the physical elements to carry out its

required function.
Product Configuration Parametric
Architecture Design Design

•i.e. defining the building blocks of the product in terms

of what they do and their interfaces

Phase II.
• Design for Human Embodiment
Factor Design

• Creating user-friendly
Design
 The Phase Of Design – Phase 2

•Establishing the shape and general dimensions of

the components.
Product Configuration Parametric
Architecture Design Design

• Components include special purpose parts,

standard
parts, standard assemblies or modules.
Phase II.
• Develop from Embodiment
function. Design

• Configuration depending on:

1. Available materials and production
methods
2. Spatial constraints
3. Product architecture
 The Phase Of Design – Phase 2

•Set the dimensions and tolerances in order to maximize

quality and performance and minimize cost. Product Configuration Parametric
Architecture Design Design

•Objective : to set values for the design variables that will

produce the best possible design considering both
performance and manufacturability.
Phase II.
Embodiment
• A few established method in designing to maximise Design
performance and quality :

– FMEA
– Design for reliability
– Robust design
– Design for Assembly (DFA)
– Design for Manufacture (DFM)
 The Phase Of Design – Phase 3

• Any missing or incomplete information are added • Final Phase- Detail design
→ arrangement, form, dimensions, tolerances,
surface properties, materials and manufacturing of • Waiting for final decision to be manufacture
each part
•The design is brought to the stage of a
•Activities to be completed in the detail design complete engineering description of a tested
phase (documentation): and producible product.

–Detail engineering drawing.

– Verification testing of prototype.
– Assembly drawings and instruction, BOM. Phase III.
– A detailed product specification. Detail Design
– Decisions either to fabricate each part or to buy it
– A detailed cost estimation.
–A design review as a conclusion of the detail
design phase before beingpassed to manufacturing.
The Phase Of Design – Phase 3
 PRINCIPLES OF DFMA

• Minimize total number of parts

• Use modular design
• Minimize part variations
• Use a multifunctional design
• Design parts for multiuse
• Design to simplify fabrication
• Use of fastener
• Minimize assembly direction
• Maximize compliance
• Minimize handling
• Eliminate or simplify adjustment
• Avoid flexible component
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 Design for Assembly (DFA)

• Simplicity – minimize part number, part variety, simplify

assembly sequences and component handling and
insertion
• Standardize – on material usage
• Use the widest possible tolerance
• Minimize non value added operations
• Choose material that suit function and production
process
• Team work
• Reduce number of parts
• Ensure that the remaining parts are easy to assemble
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 Design for Assembly Outcomes

•Shorten product design time

•Reduce assembly time
•Simplify assembly process
•Reduce total material cost
•Improves quality and reduce defects
•Reduce labour content

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Guidelines for Manual Assembly
- Handling
■ Divided into 2 areas:
- Insertion and fastening

Design Guidelines for Insertion and Fastening

■ Provide chamfers
■ Provide clearance
■ Standardize
■ Design a part whichcan be locate before it is released

Design Guidelines for Part Handling

• Avoid tangling part
• Part should have end to end symmetry
• Avoid part that stick together, small slippery and dangerous to the handler
Factors that will affect
handling
Design feature that will help
assembly process
Design to avoid adjustment during assembly
Design concept that will provide easier access during assembly
 Design For Manufacture (DFM)
• Design for ease of manufacture of the collection
of parts or product
• More as a philosophy
• It is a way of thinking that can be applied to
component or product
• Aspects to look at in DFM :
1. Operating parameters
2. Operating and non-operating environmental stimuli
3. Test requirements
4. External dimensions
5. Maintenance and testability provisions
6. Materials requirements
7. Reliability requirements
8. External surface treatment
9. Design life
10. Packaging requirements
11. External marking
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DFM 3 key element:

1.Process selection
2.Reducing the number of
process stages
3.Designing of the process
 1. Process Selection

•Analysis of material and processing

methods for individual component
based on:
-Tolerance requirement
-Production volume
-Component complexity requirement
-Critical performance criteria
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 2. Reducing Process Stages

•Eliminate unnecessary process stages

through:
-Component minimization
-Elimination of finishing process
-Combining processes

13
 3. Design of the Process

• To ensure design of component will satisfy the specific

production process
• Exploit the benefits and limitation of the process
- Design for machining
- Design for casting
- Design for injection moulding
- Design for Powder Metallurgy

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OTHER DESIGN CONSIDERATIONS

1.Product Use

2.Design Life

3.Human Factor Consideration

 1. Product Use
• “Customer is always right”

• U.S. consumer products are developed under a philosophy that the customer
will buy the cheapest product available.

• But it is hopefully not as true for engineering design products where the
customer is more sophisticated and will normally demand performance,
reliability, serviceability, reasonable cost, safe operation, and good human
engineering (ergonomics).

• Customer expectations are compared with the various product design

characteristics to identify those that are not addressed and to develop an
optimized product plan incorporating design modifications accommodating
the dominant expectations.

• Product liability in the United States is a design consideration that is growing

in importance.

• Users of products are increasingly aware of their opportunities to sue

manufacturers, and court sentiment often leans toward the consumer even
when the product misuse is involved.
 2. Design Life
• Many engineering design products are designed for a specific
installation or assembly, and it is normally assumed that they will
remain in this application for their useful life.

• Design life is in terms of cycles or hours of operation, and it is a

fairly straightforward task to design and test the product to meet
these requirements.

• Some thought needs to be given to retirement of the product after

completion of its design life.

• If the environment is to be treated as surroundings (in a

thermodynamic context), the product must be capable of being
refurbished and reused or the materials of construction must be
recyclable or biodegradable
 3. Human Factor Consideration
• All designers should consider the operator of the device, component, or
system under development and strive to produce user-friendly products.

• The term operator must include the person(s) that maintains and repairs
the product as well as the person that uses it.

• A significant amount of anthropomorphic information is available that can

be used to determine the size and location of manually actuated devices
on the product as well as the optimum location of visual elements.

• An individual's capacity for doing work should be considered in the design

and, for repetitious tasks, a system layout should be selected that
minimizes boredom but does not overload the individual's capacity to
comprehend.

• The product must be aesthetically appealing because many products are

purchased primarily due to their look and may be the feature that initially
interests the potential buyer.
 CHAPTER 3 (b)

Design Process & The Role of CAD

MEC435
COMPUTER-AIDED
DESIGN

1
 3.3 COMPUTER APPLICATIONS

• Three (3) major computer applications in

engineering environment.

1.Design
2.Analysis
3.Manufacturing

2
 Computer Application in Design

• Conceptual and also geometrical modeling design stage uses a lot of

computer application.

• Both hardware and software.

• Visualizing and styling of products for concept generation → 1st idea of

product.

• Widely usage of CAD tools → graphics and 3D modeling.

• E.g. Hardware: 3D Scanner, digitizer, pointing device etc.

• E.g. Software: AutoCAD, Pro-Engineer, Solidworks, UniGraphics, CATIA

etc.

3
 Computer Application in Analysis
• Engineering analysis and optimization design stage uses
computer application.

• Mainly for design analysis → structure, strength, heat

transfer, fluid flow etc.

• Analysis may be used as a source of design verifications for

design calculations and predictions.

• Involves CAE tools → FEA, CFD, Ergonomics etc.

• E.g. ABAQUS, ANSYS, Mannequin-Pro, CFX etc.

4
 Computer Application in Manufacturing

• Mainly used for planning, monitoring, control and

executing manufacturing processes.

• Use of CAM tools → CNC machines, software etc.

• Involves wide areas from process planning to marketing.

• E.g. Software: MasterCAM

5
 3.4 DIGITAL MOCK-UP (DMU)

• Digital Mock-Up or DMU is a concept that allows the description

of a product, usually in 3D.

• A digital mock-up comprises of 3D models which are

positioned in 3D space to represent the form of the product to
be developed.

• One of the objectives is to have an important knowledge of the

future or the supported product to replace any physical
prototypes with virtual ones, using 3D computer graphics
techniques.

6
 DMU Roles & Goals
• DMU Roles:

–Allows full visualization of complete product in 3 dimensions.

–Permits collaborative engineering as all users can see other users work as it
evolves.
–Improves error detection by locating clashes/interference's earlier in
process.

• DMU Goals :

–Reduce time-to-market by identifying potential issues earlier in the design

process.
–Reduce product development costs by minimizing the number of physical
prototypes that need to be built.
–Increase product quality by allowing a greater number of design
alternatives to be investigated before a final one is chosen.
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COMPUTER AIDED PROCESS PLANNING (CAPP)

• Process planning begins with an examination of an engineering part

drawing and ends with manufacturing process plans and instructions –
act of preparing processing documentation for the manufacturing of a
piece, part or assembly.

• Two levels of process planning:

1.High-level planning – general planning; identify, grouping, order
instruction.
2.Low-level planning – detailing the general plan above.

• Process planners follow a consistent set of steps to develop process

plans → involves primarily stock preparation, plan generation and
specification of manufacturing parameters.

8
• Traditionally process planning is performed manually by highly experienced
planners who possess in-depth knowledge of the manufacturing processes
involved and the capabilities of the shop floor facilities.

• Development of a new process plan is highly subjective, labor intensive, time

consuming, tedious and often boring.

• Computer Aided Process Planning (CAPP) is a means to automatically develop the

process plan from the geometric image of the component.

• CAPP → Fully integrates CAD and CAM.

• CAPP takes CAD data → to production data → feeds to a production system.

• Key to development of such CAPP Systems:

1.Part design
2.Manufacturing facilities
3. Manufacturing Capabilities
Basic Steps of Process Planning :

• Analysis of part requirements

• Selection of raw workpiece
• Determining manufacturing operations and their
sequences
• Selection of machine tools
• Selection of tools, work holding devices, and
inspection equipments
• Determining machine conditions ( cutting speed,
feed and depth of cut) and
Manufacturing times (setup time, lead time and
processing time )
•Benefits of CAPP:

1.Reduce process planning effort –

systematically produce accurate and consistent
process plans.
2.Saving in direct labor.
3.Saving in material.
4.Saving in scrap.
5.Saving in tooling.
6.Reduce WIP
7.Reduce process planning lead time.
8.Greater process consistency.
10
CAPP Model
Architecture of A CAPP System
 Approaches to CAPP

• Two (2) basic approaches to CAPP:

1.Variant Approach
2.Generative Approach

• A combined approach of the above two approaches →

hybrid or semi-generative approach.

13
 Variant Approach
• Also called retrieval approach.

• Uses a GT (Group Technology) code to select generic process plan

from the existing master process plans (baseline process plan)
developed for each part family and edits to suit the requirement of
the part.

• About 90% of the baseline process plan is ready. Planners only

retrieve and add another 10% by modifying the baseline plan.

• Commonly implemented with GT coding system.

• Parts are segmented into groups based on similarity and each group
has a master plan.

• Challenge is in developing initial GT classification and coding

structure for new parts.

• A new process plan must be developed manually and entered into

the system database to create a new baseline process plan.
• Impractical in situations where small batches of widely varying
parts are produced.

• Disadvantage:
–Quality of the process plan still depends on the knowledge and background of
the process planner.
–Have possibilities of repeating mistakes from earlier plans that were stored in the
database.

• Advantage:
–Good in investment where the hardware and software required for the CAPP
system is not high.
–Offer shorter development time and lower manpower to produce the process
plan.

• Implementing a variant CAPP system is straight forward since

it makes use of the existing process plans that are already
proven in the form of a catalogue from which the required
process plan need to be selected and edited.
Variant Approach to CAPP
 Generative Approach
• A process plan is created from scratch for each component without human
involvement.

• These systems are designed to automatically synthesize process information

to develop process plan for a part.

• Does require or store predefined master plan.

• Contain the logic to use manufacturing databases and suitable part

description schemes to generate process plan for a particular part.

• The process plans are generated by means of decision logic, formulas,

technology algorithm and geometry-based data.

• Most of the contemporary CAPP systems being developed applies generative

approach.

• Generative approach eliminates disadvantages of variant approach and

bridges the gap between the CAD and CAM.
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• Implementing a generative CAPP system requires far more effort. This
involves the codification of the various knowledge related to the
manufacturing resources of the enterprise and build the algorithms for
identifying the resources and plans based on the component
geometry.

• Advantage:
– Fully automatic and up-to-date process plan is generated each time a part is
ordered.

• Disadvantage:
– Require major revisions in decision logic if new equipment or processing
capabilities comes in.

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Generative Approach to CAPP
 CAPP Implementation Techniques
• Computer Aided Process Planning uses logical decision →
traditional implementation technique.

• The simplest approach is to code the process capability in a

computer program.

• E.g. tree structured classification can be used in the system and

each process can be coded as a branch of a decision tree.

• Three (3) methods:

1.Decision Table
2.Decision Tree
3.Expert System Techniques (AI)

20
 1. Decision Table
• Partitioned into conditions and actions and is
represented in a tabular form.

• A program structuring tool which provides readable

documentation as an automatic by-product.

• Can be used with preprocessor to eliminate some

program coding and to provide automatic checks for
completeness, contradiction and redundancy.

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 2. Decision Tree

• A graph with a single root and branches emanating from the root.

• Easier to customize, update, maintain, visualize and develop

compared to decision table.

• Can be represented as computer codes or data.

• The tree as computer code is converted to flowchart.

• The starting node is the root and every branch represents a decision
statement, which is either false or true.

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 3. Expert System Techniques (AI)
• The popularity of expert systems in CAPP is due to this qualitative,
subjective, imprecise and company specific nature of the process
planning knowledge.

• Designed to cope with such knowledge characteristics.

• Much easier to modify and customize than the fixed logic conventional
systems, because the knowledge in expert systems is clearly
represented and separated from the planning (presumption)
mechanism.

• Frequently used method to solve problems in AI is the theorem

proving technique.

• Artificial intelligence techniques have often been found to be useful in

generative CAPP system development.

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 3. Expert System Techniques (AI)
• The popularity of expert systems in CAPP is due to this qualitative,
subjective, imprecise and company specific nature of the process planning
knowledge.

• Designed to cope with such knowledge characteristics.

• Much easier to modify and customize than the fixed logic conventional
systems, because the knowledge in expert systems is clearly represented and
separated from the planning (presumption) mechanism.

• Frequently used method to solve problems in AI is the theorem proving

technique.

• Artificial intelligence techniques have often been found to be useful in

generative CAPP system development.

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Essential Elements of a Retrieval (Variant) Type CAPP System
Essential Elements of a Generative Type CAPP System
 Hybrid Approach
• Used when a problem in generating a purely generative process
plan occurs.

• Systems using this method must cooperate with process planners

with high technical knowledge.

• The planners responsibility is interpretation of decision data and/or a

working drawing.

• Can be done through:

– Use variant approach to develop a general process plan and then use generative
method to modify it.
– Use generative approach to generate as much process plan as possible and then
use variant approach to fill in the details.
– Select either to use generative mode for complicated part features or variant mode
for fast process plan generation.
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Interaction of various elements in Computer Aided
Process Planning (CAPP
 COMPUTER INTEGRATED
MANUFACTURING (CIM)

• CIM as defined by the Society of Manufacturing Engineers (SME):

“Integration of total manufacturing enterprise through use of

integrated systems and data communications coupled with new
managerial philosophies that improve organizational and personal
efficiency”

• Basically involves the integration of all the functions of an enterprise.

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The New Manufacturing Enterprise Wheel Suggested
by Society of Manufacturing Engineers (SME)
 6 Areas of the Manufacturing Enterprise
Wheel
1.Success of an enterprise depends on the customer.

2.Dealing with the organizational structure of the enterprise.

3.Shared knowledge → database & experience.

4.Systems that are involved and used in the total enterprise.

5.Resources and responsibilities of the enterprise.

6.Manufacturing infrastructure.
The Interaction of the Tooling system with Other
Functions in CIM
 CIM Implementation

Functions and
hierarchical
levels in CIM
Major functions in CIM
Some Interface Requirements in CIM
 Benefits of CIM
1.Improves operational control

2.Improves short run responsiveness consisting of:

• Engineering changes
• Processing changes
• Machine downtime
• Operator unavailability
• Cutting tool failure
• Late material delivery

3.Improves long run accommodation through quicker and easier assimilation of:
• Changing product volumes
• New product additions and introductions
• Different part mixes

4.Reduces inventory

5. Increase machine utilization